Coating composition, coating film, method of manufacturing coating film, and optical recording medium

ABSTRACT

A coating composition containing a solvent and a coating agent having an ionizing radiation-curable compound as a principal component thereof, wherein under the following condition for the concentration a (wt %) of the coating agent in the coating composition 
       0&lt;a≦60, 
     the concentration a of the coating agent and the surface tension b (dyne/cm) of the coating composition satisfy the following relationship 
       b≦(−a/15)+26, 
     is applied onto a surface of a protective film  11  and curing is carried out to form a hard coating layer  12 . Even in the case that projections or foreign bodies are present on the surface of the protective film  11 , the hard coating layer  12  can conceal these and hence can have high surface smoothness.

TECHNICAL FIELD

The present invention relates to a coating composition, a coating film,a method of manufacturing a coating film, and an optical recordingmedium, and in particular relates to a coating composition and a methodof manufacturing a coating film according to which a highly smoothsurface can be formed, and a coating film and an optical recordingmedium having high surface smoothness.

BACKGROUND ART

With Blu-ray Discs, which are next-generation optical discs, as withordinary optical discs, a protective film comprising a polycarbonateresin for protecting an information recording layer is bonded to theinformation recording layer; however, Blu-ray Discs have a very highcapacity and high density of recorded information, and hence errors mayoccur in reading or writing of information if the protective film isdamaged even only slightly, and thus the present state of affairs isthat Blu-ray Discs are handled while housed in a cartridge.

However, to make Blu-ray Discs more compact as media and to reduce themanufacturing cost, cartridge-less bare discs are desired.

Therefore, forming a hard coating layer 12P on the protective film 11for the information recording layer has, for example, been proposed asshown in FIG. 4 (Japanese Patent Application Laid-open No. 2002-245672).

The protective film 11 for a Blu-ray Disc or the like is generallymanufactured by casting a solution that has been obtained by diluting apolycarbonate resin with a solvent onto a belt to form a film, butprojections 10 may be formed on the surface of the protective film 11manufactured.

In the case of forming a hard coating layer 12P on the surface of aprotective film 11 having projections 10 thereon as described above,defects arise in the surface of the hard coating layer 12P nucleated bythe projections 10, leading to deterioration of signal characteristics.

Moreover, when forming the hard coating layer 12P, in the case thatforeign bodies such as dust or the like are attached to the surface ofthe protective film 11 and a coating agent for the hard coating layer12P is applied on in this state, a similar problem arises.

DISCLOSURE OF THE INVENTION

The present invention has been accomplished in view of the above stateof affairs; it is an object of the present invention to provide acoating composition and a method of manufacturing a coating filmaccording to which, even in the case that projections or foreign bodiesare present on a surface to be coated, these can be concealed and hencea highly smooth surface can be formed, and a coating film and an opticalrecording medium having high surface smoothness.

To attain the above object, the present invention firstly provides acoating composition containing a coating agent having an ionizingradiation-curable compound as a principal component thereof, the coatingcomposition characterized in that under the following condition for theconcentration a (wt %) of the coating agent in the coating composition

0<a≦60,

the concentration a of the coating agent and the surface tension b(dyne/cm) of the coating composition satisfy the following relationship

b≦(−a/15)+26  (invention 1).

According to the above invention (invention 1), even in the case thatprojections or foreign bodies are present on a surface to be coated,these can be concealed and hence a highly smooth surface can be formed.

In the case of the above invention (invention 1), the coating agentpreferably contains at least one selected from dimethylsiloxanecompounds and fluoro compounds (invention 2); in the case of containinga dimethylsiloxane compound, the content thereof is preferably 0.5 to 50wt % (invention 3), and in the case of containing a fluoro compound, thecontent thereof is preferably 0.1 to 20 wt % (invention 4).

According to the above inventions (inventions 2 to 4), it becomes easyto give the coating composition a surface tension satisfying theabove-mentioned relationship.

The present invention secondly provides a coating film comprising aresin film, and a coating layer obtained by applying a coatingcomposition as above (inventions 1 to 4) onto at least one surface ofthe resin film and performing curing (invention 5).

With the coating film according to the above invention (invention 5),because the coating layer is formed using a coating composition asabove, even in the case that projections or foreign bodies are presenton the surface of the resin film on which the coating layer is formed,these can be concealed by the coating layer, and hence a high surfacesmoothness can be obtained.

In the case of the above invention (invention 5), in the case thatprojections are present on the surface of the resin film on which thecoating layer is formed, and the maximum height of the projections is h(μm), the thickness d (μm) of the coating layer preferably satisfies thefollowing condition

d≧h+1  (invention 6).

According to the above invention (invention 6), the projections can bereliably concealed by the coating layer, and hence a very high surfacesmoothness can be obtained.

In the case of the above inventions (inventions 5 and 6), an adhesivelayer may be provided on the surface of the resin film on which thecoating layer is not formed (invention 7).

In the case of the above inventions (inventions 5 to 7), the resin filmmay comprise a material having a polymethyl methacrylate resin, apolycarbonate resin or a cycloolefin resin as a principal componentthereof (invention 8); such a coating film is suitable as a protectivelayer in an optical recording medium.

The present invention thirdly provides a method of manufacturing acoating film, comprising forming a coating layer by applying a coatingcomposition that has been obtained by adjusting the concentration of acoating agent therein having an ionizing radiation-curable compound as aprincipal component thereof onto a surface of a resin film andperforming curing, the method of manufacturing a coating filmcharacterized in that the coating composition is prepared such thatunder the following condition for the concentration a (wt %) of thecoating agent in the coating composition

0<a≦60,

the concentration a of the coating agent and the surface tension b(dyne/cm) of the coating composition satisfy the following relationship

b≦(−a/15)+26  (invention 9).

According to the above invention (invention 9), even in the case thatprojections or foreign bodies are present on the surface of the resinfilm on which the coating layer is formed, these can be concealed by thecoating layer, and hence a coating film having high surface smoothnesscan be obtained.

In the case of the above invention (invention 9), the coating layer ispreferably formed such that in the case that projections having amaximum height of h (μm) are present on the surface of the resin film onwhich the coating layer is formed, the thickness d (μm) of the coatinglayer satisfies the following condition

d≧h+1 (invention 10).

According to the above invention (invention 10), the projections can bereliably concealed by the coating layer, and hence a coating film havingvery high surface smoothness can be obtained.

The present invention fourthly provides an optical recording mediumcomprising a coating film as above (inventions 5 to 8) or a coating filmobtained using a method of manufacturing a coating film as above(inventions 9, 10) (invention 11).

The optical recording medium according to the above invention (invention11) has high surface smoothness due to the coating layer, and hencethere is no deterioration of signal characteristics due to projectionson the resin film, and thus the error rate is very low.

EFFECTS OF THE INVENTION

According to a coating composition or a method of manufacturing acoating film of the present invention, even in the case that projectionsor foreign bodies are present on a surface to be coated, these can beconcealed and hence a highly smooth surface can be formed. Moreover, acoating film or an optical recording medium of the present invention isable to have high surface smoothness even in the case that projectionsor foreign bodies are present on a surface to be coated with a coatinglayer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of a hard coating film according to anembodiment of the present invention.

FIG. 2 is a sectional view of a hard coating film according to anotherembodiment of the present invention.

FIG. 3 is a sectional view of an optical disc according to an embodimentof the present invention.

FIG. 4 is a sectional view of a conventional hard coating film.

BEST MODE FOR CARRYING OUT THE INVENTION

Following is a description of embodiments of the present invention.

[Coating Composition]

A coating composition according to the present embodiment contains acoating agent having an ionizing radiation-curable compound as aprincipal component thereof.

Examples of the ionizing radiation-curable compound are aphotopolymerizable prepolymer and/or a photopolymerizable monomer. Asphotopolymerizable prepolymers, there are radical polymerization typeones and cationic polymerization type ones; examples of radicalpolymerization type photopolymerizable prepolymers include polyesteracrylate type, epoxy acrylate type, urethane acrylate type, and polyolacrylate type ones.

A polyester acrylate type prepolymer can be obtained, for example, byesterifying with (meth)acrylic acid the hydroxyl groups of a polyesteroligomer having a hydroxyl group at each end thereof obtained throughcondensation between a polyfunctional carboxylic acid and a polyhydricalcohol, or by esterifying with (meth)acrylic acid the hydroxyl groupsat the ends of an oligomer obtained by adding an alkylene oxide to apolyfunctional carboxylic acid.

An epoxy acrylate type prepolymer can be obtained, for example, byesterifying by reacting (meth)acrylic acid with the oxirane rings of abisphenol type epoxy resin or a novolak type epoxy resin of relativelylow molecular weight.

A urethane acrylate type prepolymer can be obtained, for example, byesterifying with (meth)acrylic acid a polyurethane oligomer obtainedthrough reaction between a polyether polyol or a polyester polyol and apolyisocyanate.

A polyol acrylate type prepolymer can be obtained by esterifying with(meth)acrylic acid the hydroxyl groups of a polyether polyol.

As a cationic polymerization type photopolymerizable prepolymer, anepoxy resin is generally used. Examples of such epoxy resins includecompounds obtained by epoxidizing a polyhydric phenol such as bisphenolresins and novolak resins with epichlorohydrin or the like, andcompounds obtained by oxidizing a straight chain olefin compound or acyclic olefin compound with a peroxide or the like.

One photopolymerizable prepolymer as above can be used alone, or two ormore can be used in combination.

Examples of photopolymerizable monomers, on the other hand, includepolyfunctional acrylates such as 1,4-butanediol di(meth)acrylate,1,6-hexanediol di(meth)acrylate, neopentyl glycol di(meth)acrylate,polyethylene glycol di(meth)acrylate, neopentyl glycol adipatedi(meth)acrylate, neopentyl glycol hydroxypivalate di(meth)acrylate,dicyclopentanyl di(meth)acrylate, caprolactone-modified dicyclopentenyldi(meth)acrylate, ethylene oxide-modified phosphoric aciddi(meth)acrylate, allylated cyclohexyl di(meth)acrylate, isocyanuratedi(meth)acrylate, trimethylolpropane tri(meth)acrylate,dipentaerythritol tri(meth)acrylate, propionic acid-modifieddipentaerythritol tri(meth)acrylate, pentaerythritol tri(meth)acrylate,propylene oxide-modified trimethylolpropane tri(meth)acrylate,tris(acryloxyethyl) isocyanurate, pentaerythritol tetraacrylate,propionic acid-modified dipentaerythritol penta(meth)acrylate,dipentaerythritol hexa(meth)acrylate, and caprolactone-modifieddipentaerythritol hexa(meth)acrylate.

One photopolymerizable monomer as above can be used alone, or two ormore can be used in combination; moreover, such a photopolymerizablemonomer may be used in combination with a photopolymerizable prepolymeras described above.

In addition to an ionizing radiation-curable compound as describedabove, the coating agent may as desired contain a photopolymerizationinitiator, a filler, or another ionizing radiation-curable compound.

As a photopolymerization initiator, for a radical polymerization typephotopolymerizable prepolymer or photopolymerizable monomer, for examplebenzoin, benzoin methyl ether, benzomethyl ether, benzoinisopropylether, benzoin-butyl ether, benzoin isobutyl ether, acetophenone,dimethylaminoacetophenone, 2,2-dimethoxy-2-phenylacetophenone,2,2-diethoxy-2-phenylacetophenone,2-hydroxy-2-methyl-1-phenylpropane-1-one, 1-hydroxycyclohexyl phenylketone, 2-methyl-1-[4-(methylthio)phenyl]-2-morpholinopropane-1-one,4-(2-hydroxyethoxy)phenyl 2-(hydroxy-2-propyl) ketone, benzophenone,p-phenylbenzophenone, 4,4′-diethylaminobenzophenone,dichlorobenzophenone, 2-methylanthraquinone, 2-ethylanthraquinone,2-tertiary-butylanthraquinone, 2-aminoanthraquinone,2-methylthioxanthone, 2-ethylthioxanthone, 2-chlorothioxanthone,2,4-dimethylthioxanthone, 2,4-diethylthioxanthone, benzyl dimethylketal, acetophenone dimethyl ketal, p-dimethylaminobenzoate ester or thelike, or a high-molecular-weight photopolymerization initiator such asoligo{2-hydroxy-2-methyl-1[4-(1-methylvinyl)phenyl]propanone}, or thelike can be used.

Moreover, for a cationic polymerization type photopolymerizableprepolymer, for example a compound comprising an onium such as anaromatic sulfonium ion, an aromatic oxosulfonium ion or an aromaticiodonium ion and an anion such as tetrafluoroborate,hexafluorophosphate, hexafluoroantimonate or hexafluoroarsenate, or thelike can be used.

One photopolymerization initiator as above can be used alone, or two ormore can be used in combination. The amount added of thephotopolymerization initiator is generally 0.2 to 10 parts by weight per100 parts by weight of the total amount of the photopolymerizableprepolymers and photopolymerizable monomers.

As a filler, for example inorganic fine particles can be used to adjustthe refractive index of the coating layer obtained and increase thecured strength of the film. Examples of such inorganic fine particlesinclude silicon dioxide particles, titanium dioxide particles, aluminumoxide particles, tin oxide particles, calcium carbonate particles,barium sulfate particles, talc, kaolin, and calcium sulfate particles;the mean particle diameter thereof is preferably not more than 0.5 μm.Moreover, the inorganic fine particles may be surface-treated to improvethe stability thereof in the coating composition and strengthen thecoating layer.

Moreover, to increase the refractive index of the coating layerobtained, fine particles comprising at least one oxide of a metalselected from titanium, aluminum, indium, zinc, tin and antimony, forexample fine particles of TiO₂, Al₂O₃, In₂O₃, ZnO, SnO₂, Sb₂O₃, ITO orthe like, wherein the particle diameter is not more than 100 nm,preferably not more than 50 nm, can be used as a filler. Such metaloxide fine particles have a particle diameter sufficiently smaller thatthe wavelength of light, and hence scattering of light is not broughtabout, and thus a dispersion (coating layer) having the metal oxide fineparticles dispersed therein will behave as an optically uniformsubstance.

The amount added of the above inorganic fine particles (metal oxide fineparticles) is preferably 10 to 90 wt % of the coating agent.

Furthermore, to improve the hardness of the coating layer obtained andthus give the coating layer scratch-preventing performance, reactiveparticles, for example reactive particles as described in JapanesePatent Application Laid-open No. 2000-273272, can be used as an ionizingradiation-curable compound. Such reactive particles comprise inorganicoxide particles having chemically bonded thereto an organic compound (a)having at least one polymerizable unsaturated group in the moleculethereof.

Examples of the inorganic oxide particles in the reactive particles areparticles of silica, alumina, zirconia, titanium oxide, zinc oxide,germanium oxide, indium oxide, tin oxide, antimony oxide, cerium oxideor the like; one of these can be used alone, or two or more can be usedin combination.

In the case of using the coating composition to form a coating layer(hard coating layer) on an optical film, an optical product or the like,it is preferable to use silica particles, which absorb little light andhave high optical transparency, as the inorganic oxide particles.

The mean particle diameter of the inorganic oxide particles ispreferably 0.001 to 2 μm, particularly preferably 0.001 to 0.2 μm, yetmore preferably 0.001 to 0.1 μm. If the mean particle diameter of theinorganic oxide particles exceeds 2 μm, then the optical transparency ofthe coating layer obtained upon curing the coating composition may drop,and the surface smoothness of the coating layer may be poor.

The form of the inorganic oxide particles may be any of spherical,hollow, porous, rod-like, plate-like, fiber-like, irregular-shaped andso on, but is particularly preferably spherical.

The specific surface area (the specific surface area according to a BETmethod using nitrogen) of the inorganic oxide particles is preferably 10to 1000 m²/g, particularly preferably 100 to 500 m²/g.

Examples of the polymerizable unsaturated group possessed by the organiccompound (a) bonded to the inorganic oxide particles include an acryloylgroup, a methacryloyl group, a vinyl group, a propenyl group, abutadienyl group, a styryl group, an ethynyl group, a cinnamoyl group, amaleate group, and an acrylamide group.

There are no particular limitations on the number of polymerizableunsaturated groups in the organic compound (a) so long as this number isat least one per molecule, but this number is generally 1 to 4.

In addition to such a polymerizable unsaturated group, the organiccompound (a) preferably contains a group represented by the formula—X—C(═Y)—NH— (in the formula, X is NH, O or S, and Y is O or S).Moreover, the organic compound (a) is preferably a compound having asilanol group in the molecule thereof, or a compound in which a silanolgroup is produced upon hydrolysis.

A preferable specific example of such an organic compound (a) is, forexample, a compound represented by undermentioned formula (1).

In formula (1), R¹ and R² are each a hydrogen atom or an alkyl group oraryl group having 1 to 8 carbon atoms, and may be the same or different.Examples of such a functional group include a methyl group, an ethylgroup, a propyl group, a butyl group, an octyl group, a phenyl group,and a xylyl group.

Examples of the group represented by the formula (R¹O)_(m)R² _(3-m)Si—include, for example, a trimethoxysilyl group, a triethoxysilyl group, atriphenoxysilyl group, a methyldimethoxysilyl group, and adimethylmethoxysilyl group; out of these, a trimethoxysilyl group, atriethoxysilyl group or the like is preferable. Here, m is an integerfrom 1 to 3.

R³ is a bivalent organic group having an aliphatic or aromatic structurewith 1 to 12 carbon atoms, and may contain a chain, branched or cyclicstructure. Examples of such an organic group include a methylene group,an ethylene group, a propylene group, a butylene group, a hexamethylenegroup, a cyclohexylene group, a phenylene group, a xylylene group, and adodecamethylene group; out of these, a methylene group, a propylenegroup, a cyclohexylene group, a phenylene group or the like ispreferable.

R⁴ is a bivalent organic group, and is generally selected from bivalentorganic groups having a molecular weight of 14 to 10,000, preferably 76to 500. Examples of such bivalent organic groups are chain polyalkylenegroups such as hexamethylene, octamethylene and dodecamethylene,alicyclic and multi-ring bivalent organic groups such as cyclohexyleneand norbornylene, bivalent aromatic groups such as phenylene,naphthylene, biphenylene and polyphenylene, and alkyl group-substitutedor aryl group-substituted derivatives of the above. Such a bivalentorganic group may contain atomic groups containing atoms other thancarbon and hydrogen atoms, and moreover may contain polyether linkages,polyester linkages, polyamide linkages or polycarbonate linkages, orgroups represented by the formula —X—C(═Y)—NH— (in the formula, Xrepresents NH, O or S, and Y represents O or S).

R⁵ is an organic group of valency n+1, and is preferably selected fromchain, branched and cyclic saturated hydrocarbon groups and unsaturatedhydrocarbon groups. Here, n is preferably an integer from 1 to 20,particularly preferably 1 to 10, yet more preferably 1 to 5.

Z is a monovalent organic group having in the molecule thereof apolymerizable unsaturated group that is able to undergo anintermolecular crosslinking reaction under the presence of an activeradical species. Examples of such organic groups include anacryloyl(oxy) group, a methacryloyl(oxy) group, a vinyl(oxy) group, apropenyl(oxy) group, a butadienyl(oxy) group, a styryl(oxy) group, anethynyl(oxy) group, a cinnamoyl(oxy) group, a maleate group, anacrylamide group, and a methacrylamide group; out of these, anacryloyl(oxy) group and a methacryloyl(oxy) group are preferable.

The reactive particles can be manufactured by reacting the inorganicoxide particles and the organic compound (a) together. It is thoughtthat a component able to react with the organic compound (a) is presenton the surface of the inorganic oxide particles, and hence by mixingtogether the organic compound (a) and the inorganic oxide particles inthe form of a powder or a solvent dispersion sol of the inorganic oxideparticles either under or not under the presence of water, and heatingand stirring, the surface component of the inorganic oxide particles andthe organic compound (a) can be reacted together, whereby the reactiveparticles are obtained.

The content (in terms of solids) of the reactive particles in thecoating agent is preferably 5 to 80 wt %, particularly preferably 10 to70 wt %.

If the content of the reactive particles is less than 5 wt %, then thehardness of the coating layer obtained may be insufficient, whereas ifthe content of the reactive particles exceeds 90 wt %, then thecurability of the coating composition may become poor.

The coating agent in the present embodiment preferably contains adimethylsiloxane compound and/or a fluoro compound so that the coatingcomposition can have a surface tension as described later.

Examples of a dimethylsiloxane compound include a mercapto-modifiedpolydimethylsiloxane, a phenol-modified polydimethylsiloxane, apolyether-modified polydimethylsiloxane, a fatty acid ester-modifiedpolydimethylsiloxane, a (meth)acrylate-modified polydimethylsiloxane,and a silicone graft acrylic resin having a dimethylsiloxane skeleton.

The content of the dimethylsiloxane compound in the coating agent ispreferably 0.5 to 50 wt %, particularly preferably 0.5 to 5 wt %.

Examples of a fluoro compound include compounds having a fluoroalkylgroup such as fluoroalkyl carboxylates, fluoroalkyl quaternary ammoniumsalts and fluoroalkyl ethylene oxide adducts, compounds having aperfluoroalkyl group such as perfluoroalkyl carboxylates, perfluoroalkylquaternary ammonium salts and perfluoroalkyl ethylene oxide adducts,compounds having a fluorocarbon group, tetrafluoroethylene polymers,copolymers between vinylidene fluoride and tetrafluoroethylene,copolymers between vinylidene fluoride and hexafluoropropylene,fluorine-containing (meth)acrylic acid esters, fluorine-containing(meth)acrylic acid ester polymers, fluorine-containing (meth)acrylicacid alkyl ester polymers, and copolymers between fluorine-containing(meth)acrylic acid esters and other monomers.

The content of the fluoro compound in the coating agent is preferably0.5 to 20 wt %, particularly preferably 0.5 to 5 wt %.

The coating composition according to the present embodiment preferablycontains a solvent, whereby it becomes easy to make the concentration ofthe coating agent and the surface tension of the coating compositionsatisfy the relationship described later. There are no limitations onthe solvent in the present embodiment so long as the solvent candissolve the ionizing radiation-curable compound in the coating agentand does not have adverse effects on the object coated; for example, thesolvent used can be selected as appropriate from alcohols such asmethanol, ethanol, isopropanol, isobutanol and octanol, ketones such asacetone, methylethylketone, methyl isobutyl ketone and cyclohexanone,esters such as ethyl acetate, butyl acetate, ethyl lactate andγ-butyrolactone, ethers such as ethylene glycol monomethyl ether (methylcellosolve), ethylene glycol monoethyl ether (ethyl cellosolve),diethylene glycol monobutyl ether (butyl cellosolve) and propyleneglycol monomethyl ether, aromatic hydrocarbons such as benzene, tolueneand xylene, and amides such as dimethylformamide, dimethylacetamide andN-methylpyrrolidone.

In addition to the above components, the coating agent in the presentembodiment may contain any of various additives such as antioxidants,ultraviolet absorbents, light stabilizers, silane coupling agents, ageresisters, thermal polymerization inhibitors, colorants, levelingagents, surfactants, storage stabilizers, plasticizers, lubricants,organic fillers, fillers, wettability improvers, and coating surfaceimprovers.

For the coating composition according to the present embodiment, underthe following condition for the concentration a (wt %) of the coatingagent in the coating composition

0<a≦60,

the concentration a of the coating agent and the surface tension b(dyne/cm) of the coating composition satisfy the following relationship

b≦(−a/15)+26.

Through the concentration a of the coating agent and the surface tensionb of the coating composition satisfying the above relationship, even inthe case that projections or foreign bodies are present on the surfaceto be coated, these can be concealed by the coating layer and hence ahighly smooth surface can be formed. Regarding the above relationship,if b>(−a/15)+26, then not only will the above effect be poor, butmoreover a problem of a reduction in the working efficiency for thecoating composition being brought about will arise.

By applying the coating composition described above onto a desiredsubstrate and curing, a coating layer, if desired a hard coating layer,having high surface smoothness can be formed on the surface of thesubstrate. Examples of the substrate subjected to the coating includeplastic products such as plastic films, plastic sheets and plasticplates, and also metal products, glass products, stone and so on.

[Coating Film]

In the present embodiment, description will be given taking a hardcoating film for protecting an information recording layer of an opticaldisc as an example of the coating film, but the coating film of thepresent invention is not limited to this usage.

As shown in FIG. 1, the hard coating film 1 according to the presentembodiment comprises a protective film 11, and a hard coating layer 12formed on one surface of the protective film 11.

It is preferable for the protective film 11 to have a sufficient opticaltransparency in a wavelength region of light for reading or writinginformation, to have suitable degrees of rigidity and flexibility sothat the optical disc can be manufactured easily, and moreover to bestable to temperature for storage of the optical disc. As such aprotective film 11, an optically transparent film having as a principalcomponent thereof a polycarbonate, a cycloolefin polymer or polymethylmethacrylate is preferable, with a film having as a principal componentthereof a polycarbonate which has high adhesiveness to the hard coatinglayer 12 described below being particularly preferable. Note that in thecase of using a film having a cycloolefin polymer as a principalcomponent thereof, it is preferable to subject the surface on which thehard coating layer 12 is to be formed to corona discharge treatment soas to improve the adhesiveness to the hard coating layer 12.

The thickness of the protective film 11 is set in accordance with thetype of the optical disc and the thickness of other constituent parts ofthe optical disc, but is generally approximately 25 to 300 μm,preferably approximately 50 to 200 μm.

The protective film 11 is generally manufactured by casting a solutionthat has been obtained by diluting a desired resin with a solvent onto abelt to form a film; projections 10 may often be formed on the surfaceof the protective film 11, and moreover projections 10 may be formedthrough foreign bodies being attached to the protective film 11. Theheight of such projections 10 is generally approximately 0.1 to 10 μm.

The hard coating layer 12 is formed by applying a coating composition asdescribed earlier, preferably a coating composition containing a filler,onto the surface of the protective film 11 and curing.

The application of the coating composition may be carried out using anordinary method, for example bar coating, knife coating, roll coating,blade coating, die coating, or gravure coating. After the application ofthe coating composition, the coating film is preferably dried atapproximately 50 to 120° C.

The curing of the coating composition can be carried out by irradiatingthe coating film of the coating composition with ionizing radiation. Asthe ionizing radiation, in general ultraviolet rays, electron rays orthe like are used. The ionizing radiation irradiation amount variesaccording to the type of the ionizing radiation, but, for example, inthe case of ultraviolet rays, approximately 100 to 500 mJ/cm² in termsof the amount of radiation is preferable, and in the case of electronrays, approximately 10 to 1000 krad is preferable.

The thickness of the hard coating layer 12 is preferably at least h+1(μm) where h (μm) is the maximum height of the projections 10. As aresult, the projections 10 can be reliably concealed, and hence a veryhigh surface smoothness can be obtained. There are no particularlimitations on the upper limit of the thickness of the hard coatinglayer 12, but to prevent warping of the hard coating film 1 obtained,this upper limit is preferably made to be not more than 20 μm,particularly preferably not more than 10 μm.

Because the hard coating film 1 according to the present embodiment hasthe hard coating layer 12 obtained by curing the coating composition asdescribed above, even in the case that projections 10 are present on thesurface of the protective film 11, these projections 10 can be concealedand hence high surface smoothness can be obtained.

The hard coating film 1 according to the present embodiment comprisesthe protective film 11 and the hard coating layer 12, but as with thehard coating film 1′ shown in FIG. 2, an adhesive layer 23 may be formedon the opposite surface of the protective film 11 to the hard coatinglayer 12, and a release sheet 3 may be further formed on the adhesivelayer 23.

There are no particular limitations on the type of an adhesiveconstituting the adhesive layer 23 so long as the optical disc can beformed; for example, the adhesive may be a pressure-sensitive adhesiveor curable pressure-sensitive adhesive of an acrylic type, a polyestertype, a urethane type, a rubber type, a silicone type or the like, or anadhesive that is ionizing radiation-curable, thermosetting,thermoplastic or the like.

The thickness of the adhesive layer 23 is generally approximately 5 to100 μm, preferably approximately 10 to 30 μm.

As the release sheet 3, a conventional publicly known one can be used;for example, one obtained by subjecting a film of a resin such aspolyethylene terephthalate or polypropylene to release treatment with asilicone release agent or the like can be used.

[Optical Disc]

As shown in FIG. 3, an optical disc 2 according to the presentembodiment comprises an optical disc substrate 21 having thereon anconcavity-convexity pattern (pits or grooves/lands), an informationrecording layer 22 formed on the concavity-convexity surface of theoptical disc substrate 21, an adhesive layer 23 formed on theinformation recording layer 22, a protective film 11 formed on theadhesive layer 23, and a hard coating layer 12 formed on the protectivefilm 11.

Such an optical disc 2 can be manufactured, for example, using a methodsuch as the following.

(1) An adhesive such as an ionizing radiation-curable adhesive isapplied onto the rear surface (the surface on which the hard coatinglayer 12 is not present; likewise hereinafter) of the hard coating film1 or onto the information recording layer 22 formed on theconcavity-convexity surface of the optical disc substrate 21, and thehard coating film 1 and the information recording layer 22 are bondedtogether.(2) A pressure-sensitive adhesive layer (pressure-sensitive adhesivesheet) comprising a pressure-sensitive adhesive of an acrylic type, apolyester type, a urethane type, a rubber type, a silicone type or thelike having a release sheet thereon is stuck onto the rear surface ofthe hard coating film 1 or the information recording layer 22 formed onthe concavity-convexity surface of the optical disc substrate 21, therelease sheet is peeled off, and the hard coating film 1 and theinformation recording layer 22 are bonded together via thepressure-sensitive adhesive layer thus exposed.(3) The release sheet 3 of the hard coating film 1′ is peeled off toexpose the adhesive layer 23, and this adhesive layer 23 and theinformation recording layer 22 formed on the concavity-convexity surfaceof the optical disc substrate 21 are bonded together.

With the optical disc 2 according to the present embodiment, projections10 present on the hard coating layer 12 side of the protective film 11are concealed by the hard coating layer 12, and hence the optical disc 2(hard coating layer 12) has high surface smoothness; there is thus nodeterioration of signal characteristics due to the projections 10, andhence the error rate is very low.

Note that the optical disc 2 according to the present embodiment is of asingle-sided one-layer type, but there are no particular limitations onthe form of the optical disc, which may also be a single-sided two-layertype.

EXAMPLES

Following is a more detailed description of the present inventionthrough examples and so on; however, the scope of the present inventionis not limited by these examples and so on.

Example 1

100 parts by weight of a urethane acrylate type prepolymer (made byArakawa Chemical Industries, Ltd., trade name ‘Beamset 575CB’, solidconcentration 100 wt %, contains photopolymerization initiator) as anionizing radiation-curable compound, and 5 parts by weight of adimethylsiloxane compound (made by BYK-Chemie Japan, trade name‘BYK-300’, solid concentration 52 wt %) were mixed together to produce acoating agent, and propylene glycol monomethyl ether was further addedas a solvent, thus preparing a coating composition having a coatingagent concentration (a) of 15, 35 or 60 wt %. The content of thedimethylsiloxane compound in the coating agent was 2.5 wt %. The surfacetension of each coating composition obtained was measured using asurface tensiometer (made by Kyowa Interface Science Co., Ltd., tradename ‘CBVP-A’) (likewise hereinafter). The surface tension measurementresults are shown in Table 1.

Each of the coating compositions was applied using a bar coater suchthat the thickness of the coating layer after drying would be 5.5 μmonto a surface having thereon projecting defects of a polycarbonate film(made by Teijin Chemicals Ltd., trade name ‘Pureace C110-75’, thickness75 μm) having thereon countless projecting defects of maximum height 4.1μm, drying was carried out for 1 minute at 70° C., and then irradiationwas carried out with ultraviolet radiation (irradiation conditions:intensity 310 mW/cm², amount of radiation 300 mJ/cm²), thusmanufacturing a hard coating film (coating film) having a hard coatinglayer.

Example 2

25 parts by weight of a urethane acrylate type prepolymer (made byArakawa Chemical Industries, Ltd., trade name ‘Beamset 575CB’, solidconcentration 100 wt %, contains photopolymerization initiator) and 100parts by weight of reactive particles (made by JSR, trade name ‘DesoliteZ7524’, solid concentration 75 wt %) as ionizing radiation-curablecompounds, and 5 parts by weight of a dimethylsiloxane compound (made byBYK-Chemie Japan, trade name ‘BYK-300’, solid concentration 52 wt %)were mixed together to produce a coating agent, and propylene glycolmonomethyl ether was further added as a solvent, thus obtaining acoating composition having a coating agent concentration (a) of 15, 35or 60 wt %. The content of the dimethylsiloxane compound in the coatingagent was 2.5 wt %. The results of measuring the surface tension of eachcoating composition obtained are shown in Table 1.

Using each of the coating compositions, a hard coating film (coatingfilm) was produced as in Example 1.

Example 3

Coating compositions were prepared as in Example 1, except that the 5parts by weight of the dimethylsiloxane compound in Example 1 waschanged to 1 part by weight of a fluoro compound (made by Dainippon Inkand Chemicals, Inc., trade name ‘MEGAFAC F-470’, solid concentration 100wt %). The content of the fluoro compound in the coating agent was 1.0wt %. The results of measuring the surface tension of each coatingcomposition obtained are shown in Table 1.

Using each of the coating compositions, a hard coating film (coatingfilm) was produced as in Example 1.

Example 4

Coating compositions were prepared as in Example 1, except that theamount of the dimethylsiloxane compound in Example 1 was made to be 2.94parts by weight, and 0.5 parts by weight of a fluoro compound (made byDainippon Ink and Chemicals, Inc., trade name ‘MEGAFAC F-470’, solidconcentration 100 wt %) was further added. The content of thedimethylsiloxane compound in the coating agent was 1.5 wt %, and thecontent of the fluoro compound was 0.5 wt %. The results of measuringthe surface tension of each coating composition obtained are shown inTable 1.

Using each of the coating compositions, a hard coating film (coatingfilm) was produced as in Example 1.

Example 5

Coating compositions were prepared as in Example 1, except that thesolvent was made to be isobutanol. The results of measuring the surfacetension of each coating composition obtained are shown in Table 1.

Using each of the coating compositions, a hard coating film (coatingfilm) was produced as in Example 1.

Example 6

Hard coating films (coating films) were produced as in Example 1, exceptthat each of the coating compositions obtained in Example 1 was appliedon such that the thickness of the coating layer after drying would be4.5 μm.

Comparative Example 1

Coating compositions were prepared as in Example 1, except that theamount of the dimethylsiloxane compound was made to be 0.15 parts byweight. The content of the dimethylsiloxane compound in the coatingagent was 0.078 wt %. The results of measuring the surface tension ofeach coating composition obtained are shown in Table 1.

Using each of the coating compositions, a hard coating film (coatingfilm) was produced as in Example 1.

Comparative Example 2

Coating compositions were prepared as in Example 3, except that theamount of the fluoro compound was made to be 0.05 parts by weight. Thecontent of the fluoro compound in the coating agent was 0.05 wt %. Theresults of measuring the surface tension of each coating compositionobtained are shown in Table 1.

Using each of the coating compositions, a hard coating film (coatingfilm) was produced as in Example 1.

Test Example

The number of defects (projections due to projections on thepolycarbonate film) present on the surface of each hard coating filmproduced in the Examples and Comparative Examples was counted, and wasconverted into the number of defects over the surface area of onesurface of an optical disc (436 cm²). The defects counted were made tobe ones having a diameter of at least 100 μm, and the counting wascarried out using a confocal microscope (made by Lasertech Corporation,HD100D). The results are shown in Table 1.

TABLE 1 b (dyne/cm) Number of a: 15 wt % a: 35 wt % a: 60 wt % defectsExample 1 23.0 21.7 21.0 0 Example 2 23.2 21.6 19.6 0 Example 3 24.523.0 21.2 0 Example 4 23.1 21.8 21.2 0 Example 5 22.3 22.6 21.8 0Example 6 23.0 21.7 21.0 20 Comparative 27.0 27.4 27.2 400 Example 1Comparative 25.8 24.0 22.8 300 Example 2

As is clear from Table 1, defects of diameter at least 100 μm were notseen at all for the hard coating films produced in Examples 1 to 5, andthere were very few such defects for the hard coating films produced inExample 6.

INDUSTRIAL APPLICABILITY

A coating composition of the present invention is suitable for forming ahard coating layer on a desired substrate, in particular a resin film,and a coating film of the present invention is suitable as a protectivefilm for an optical product, in particular an optical recording medium.

1-11. (canceled)
 12. An optical recording medium having a coating filmcomprising: a resin film; and a coating layer obtained by applying acoating composition onto one surface of said resin film and performingcuring, said coating composition contains a coating agent having anionizing radiation-curable compound as a principal component thereof,and under the following condition for the concentration a (wt %) of saidcoating agent in the coating composition0<a≦60, the concentration a of said coating agent and the surfacetension b (dyne/cm) of the coating composition satisfy the followingrelationshipb≦(−a/15)+26.
 13. The optical recording medium according to claim 12,wherein projections are present on the surface of said resin film onwhich said coating layer is formed, and the maximum height of saidprojections is h (μm), the thickness d (μm) of said coating layersatisfies the following conditiond≧h+1.
 14. The optical recording medium according to claim 12, whereinan adhesive layer is provided on the surface of said resin film on whichsaid coating layer is not formed.
 15. The optical recording mediumaccording to claim 12, wherein said resin film comprises a materialhaving a polymethyl methacrylate resin, a polycarbonate resin or acycloolefin resin as a principal component thereof.
 16. An opticalrecording medium having a coating film obtained using a method,comprising forming a coating layer by applying a coating compositionthat has been obtained by adjusting the concentration of a coating agenttherein having an ionizing radiation-curable compound as a principalcomponent thereof onto a surface of a resin film and performing curing,and said coating composition is prepared such that under the followingcondition for the concentration a (wt %) of said coating agent in saidcoating composition0<a≦60, the concentration a of said coating agent and the surfacetension b (dyne/cm) of said coating composition satisfy the followingrelationshipb≦(−a/15)+26.
 17. The optical recording medium according to claim 16,wherein said coating layer is formed such that in the case thatprojections having a maximum height of h (μm) are present on the surfaceof said resin film on which said coating layer is formed, the thicknessd (μm) of said coating layer satisfies the following conditiond≧h+1.